Graco Hydra-Clean 1040 Use and care manual

Repair/Parts
SaniForce® SaniForce®
SaniForce®1040 1040 1040Air Air Air- - -Operated Operated OperatedHigh High High
Sanitation Sanitation
SanitationDiaphragm Diaphragm DiaphragmPump Pump Pump3A6780E
EN
For For
Fortransfer transfer transferof of of󰘱uids 󰘱uids 󰘱uidsin in insanitary sanitary sanitaryapplications. applications. applications.Not Not Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or or
hazardous hazardous
hazardous(classi󰘰ed) (classi󰘰ed) (classi󰘰ed)locations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See SeeApprovals Approvals Approvalspage page pagefor for formore more moreinformation. information. information.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandrelated
manualsbeforeusingtheequipment.Save Save
Saveall all allinstructions. instructions. instructions.
120psi(0.8MPa,8bar)MaximumFluid
WorkingPressure
120psi(0.8MPa,8bar)MaximumAir
InputPressure
Seepage6forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................5
OrderingInformation...........................................6
Troubleshooting..................................................7
Repair................................................................9
PressureReliefProcedure............................9
AirValveRepair...........................................9
CheckValveRepair.....................................12
StandardDiaphragmRepair.........................13
OvermoldedDiaphragmRepair.....................15
CenterSectionRepair..................................18
Parts..................................................................20
Diaphragms.................................................23
TechnicalSpeci󰘰cations......................................25
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5999SaniForceHighSanitationDiaphragmPumps,Operation
23A6780E

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolvent,inwork work
workarea area areacanigniteorexplode.Solvent󰘱owingthrough
theequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygrounded󰘱uidlines.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
•Routeexhaustawayfromallignitionsources.Ifdiaphragmruptures,󰘱uidmaybeexhausted
withair.
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Check󰘱uidlines,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
3A6780E3

Warnings
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.
Forcompleteinformationaboutyourmaterial,requestSafetyDataSheet(SDS)from
distributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Route󰘱uidlinesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhot
surfaces.
•Donotkinkoroverbend󰘱uidlinesoruse󰘱uidlinestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Routeexhaustawayfromworkarea.Ifdiaphragmruptures,󰘱uidmaybeexhaustedinto
theair.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
43A6780E

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Whenyoureceiveyourpump,recordthe9character
partnumberfoundontheshippingbox(e.g.,
SP1B.0018):_____________
Alsorecordthecon󰘰gurationnumberonthepumpID
platetoassistyouwhenorderingreplacementparts:
_____________________________________
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:1040HS.PSP1ASSASSPTPSEP21 1040HS.PSP1ASSASSPTPSEP21
1040HS.PSP1ASSASSPTPSEP21
1040 1040
1040HS HS HSP P
PSP1A SP1A
SP1ASSA SSA SSASS SS SSPT PT
PTPS PS
PSEP EP
EP21 21
21
Pump
Model
WettedSection
Material
DriveCenterSectionandAir
ValveMaterial
ManifoldsSeatsChecksDiaphragmsSealsCerti󰘰ca-
tion
NOTE: NOTE:
NOTE:Somecombinationsarenotpossible.Pleasecheckwithyourlocalsupplier.
Pump Pump
PumpWetted Wetted
WettedSection Section Section
Material Material
Material
Drive Drive
DriveType Type TypeCenter Center
CenterSection Section Sectionand and andAir Air AirValve Valve Valve
Material Material
Material
Manifolds Manifolds
Manifolds
1040 1040
1040HS HS HSHighSanitationP P
PPneumatic
S01A S01A
S01A
StainlessSteel,for
allbut2-piecePS
diaphragms
SSA SSA
SSAStainlesssteel,
TriClamp,center-ported
PH PH
PHPharmaceuticalS03A S03A
S03AStainlessSteel,PH,
forallbut2-piecePS
diaphragms
SSB SSB
SSBStainlesssteel,DIN,
center-ported
SP1A SP1A
SP1A
StainlessSteel,
PSdiaphragms,
for2-piecePS
diaphragmsonly
SP3A SP3A
SP3AStainlessSteel,
PH,for2-piecePS
diaphragmsonly
Seat Seat
SeatMaterial Material MaterialChecks Checks ChecksDiaphragm Diaphragm
DiaphragmMaterial Material MaterialSeals Seals
SealsCerti󰘰cation Certi󰘰cation Certi󰘰cation
SS SS
SS316Stainless
Steel,BallBN BN
BNBuna-NBN BN BNBuna-NBN BN BNBuna-N21 21
21EN10204
type2.1
CW CW
CWPolychloroprene
WeightedBallFK FK
FKFKM
FluoroelastomerEP EP
EPEPDM31 31
31EN10204
type3.1
FK FK
FKFKM
Fluoroelastomer
Ball
PO PO
POPTFE/EPDM
OvermoldFK FK
FKFKM
PT PT
PTPTFEBallPS PS
PSPTFE/
Santoprene,2
piece
SP SP
SPSantopreneBallSP SP
SPSantoprene
3A6780E5

OrderingInformation
Approvals Approvals
Approvals
Allpumpsareapprovedto:
II2GD
ExhIIAT6...T3Gb
ExhIIIBT160°CDb
Modelswhichusediaphragmmaterials
codedPOorPScombinedwithPTball
checkscomplywith:
EC1935/2004
DiaphragmmaterialscodedPScombined
withPTballcheckscomplywith:
ClassVI
Allmodelsareapprovedto:
All󰘱uidcontactmaterialsareFDAcompliant
andmeettheUnitedStatesCodeofFederal
Regulations(CFR)
ATEXT-coderatingisdependentonthetemperatureofthe󰘱uidbeingpumped.Fluidtemperatureislimited
bythematerialsofthepumpinteriorwettedparts.SeeTechnicalSpeci󰘰cations,page25,forthemaximum
󰘱uidoperatingtemperatureforyourspeci󰘰cpumpmodel.
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
1.Visitwww.graco.com.
2.ClickonWhere Where
Whereto to toBuy Buy BuyandusetheDistributor Distributor DistributorLocator. Locator. Locator.
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New NewPump Pump Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm DiaphragmPump Pump PumpSelector Selector Selectorat at atwww.graco.com www.graco.com www.graco.com. . .Tolocate,searchonselector selector selector.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
63A6780E

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page9,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpcyclesatstallor
failstoholdpressureat
stall.
Wornchecksorseatingsurfaces.Replace.
Airvalveisstuckordirty.Disassembleandcleanairvalve.
Use󰘰lteredair.
Checkballisseverelywornand
wedgedinseatormanifold.
Replaceballandseat.
Checkvalveballisseverelywedged
intoseatduetooverpressurization.
Follow
PressureReliefProcedure,page9.
Disassembleballcheckassembly
andinspectfordamage.
Cloggeddispensingvalve.Follow
PressureReliefProcedure,page9.
Clearvalve.
Pumpwillnotcycle,or
cyclesonceandstops.
Leakdetectorhasactivatedashut-
downsolenoid.
Investigatefailureandresetleak
detector.
Cloggedsuctionline.Inspect;clear.
Stickyorleakingcheckballs.Cleanorreplace.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Reducedpump
performance.
Restrictedexhaust.Removerestriction.
Loosesuctionline.Tighten.
Ruptureddiaphragm.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airbubblesin󰘱uid.
Looseinletmanifold,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
gasketsorseatingsurfaces.
Loosesanitaryclamp.Tightenclamp.
Damagedorworngasket.Replacegasket.
Leakininletoroutlet
sanitary󰘰tting.
Misalignmentofinlet/outlet󰘱uidline
orpipe.
Use󰘱exible󰘱uidlinesatpumpinlet
andoutlet.
Manifoldsdonot󰘰tfor
installationonto󰘱uid
covers.
Useofincorrectaircovergaskets
resultsinmisalignment.
Installcorrectaircovergasketsfor
thetypeofdiaphragmsinuse.See
Partslistforcorrectgasket.
3A6780E7

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Diaphragmruptured.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Fluidinexhaustair.
Loosediaphragmplate.Tightenorreplace.Seestandard
orovermoldeddiaphragmrepair
procedure.
Wornairvalveblock,plate,pilot
block,u-cups,orpilotpino-rings.
Repairorreplace. Pumpexhaustsexcessive
airatstall.
Wornshaftseals.Replace.Seestandardor
overmoldeddiaphragmrepair
procedure.
Airvalvecoverisloose.Tightenscrews.
Airvalvegasketoraircovergasket
isdamaged.
Inspect;replace.
Pumpleaksairexternally.
AircoverclampsarelooseTightenclamps.
Pumpleaks󰘱uid
externallyfromballcheck
valves.
Loosemanifolds,damagedseal
betweenmanifoldand󰘱uidcover,or
damagedgaskets.
Tightenmanifoldclampsorreplace
seatsorclamps.
Chattering.Checkvalveballsnotseating
properly/cleanlyduetoimbalance
between󰘱uidinletandoutletline
sizing.Noiseisaccentuatedwith
lightviscosity󰘱uids.
Reducesize/diameterofinletline
relativetooutletline.Outletlinesize
shouldnotexceedpumpsize.
83A6780E

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
frompressurized󰘱uid,suchassplashing󰘱uid,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyou
stopdispensingandbeforecleaning,checking,or
servicingtheequipment.
1.Closethemasterairvalve(A)toshutofftheair
tothepump.
2.Openoutbound󰘱uidvalvetorelieve󰘱uid
pressurefromthepump.
3.If󰘱uidisstillintheoutbound󰘱uidlines,isolate
this󰘱uidasfollows:
a.For For
Forsimple simple simpletransfer transfer transferapplications, applications, applications,openeither
the󰘱uidshutoffvalve(J)orthe󰘱uiddrain
valve(K).
b.For For
Forcirculating circulating circulatingapplications, applications, applications,ensurethatthe
󰘱uidshutoffvalve(J)isclosedandopenthe
󰘱uiddrainvalve(K).
Air Air
AirValve Valve ValveRepair Repair Repair
ToolsRequired
•Torquewrench
•Torx(T20)screwdriveror7mm(9/32in.)socket
wrench
•Needle-nosepliers
•O-ringpick
•Lithiumbasegrease
Airvalverepairkit255122isavailable.Useallparts
inthekitforbestresults.
Disassemble Disassemble
DisassembleAir Air AirValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
2.WithaTorx(T20)screwdriveror7mm(9/32in.)
socketwrench,removethesixscrews(107),air
valvecover(109),andgasket(118).
3.Movethevalvecarriage(105)tothecenter
positionandpullitoutofthecavity.Usinga
needle-nosepliers,pullthepilotblock(116)
straightupandoutofthecavity.
4.Pullthetwoactuatorpistons(114).Removethe
u-cups(106)fromthepistons.Pullthepilotpins
(112).Removetheo-rings(108)fromthepilot
pins.
3A6780E9

Repair
5.Inspectthevalveplate(110)inplace.If
damaged,useaTorx(T20)screwdriveror7mm
(9/32)in.)socketwrenchtoremovethethree
screws(107).Removethevalveplate(110).
6.Inspectthebearings(113,115)inplace.See
Parts,page20.Thebearingsaretaperedand,
ifdamaged,mustberemovedfromtheoutside.
Thisrequiresdisassemblyofthe󰘱uidsection.
SeeCenterSectionRepair,page18.
7.Cleanallpartsandinspectforwearordamage.
Replaceasneeded.
Reassemble Reassemble
ReassembleAir Air AirValve Valve Valve
NOTE: NOTE:
NOTE:Ifrepairsinvolveremoving
󰘱uidcovers,performthestepsin
ReassembletheOvermoldedDiaphragms,page16,
priortoreassemblyoftheairvalve.Theairvalve
con󰘰gurationwillbemodi󰘰edtoaid󰘱uidcover
installation.
1.Ifthecentersectionwasdisassembledto
replacethebearings(113,115),complete
theCenterSectionRepair,page18,before
continuingwiththeairvalvereassembly.
2.Installthevalveplate(110)inthecavity,seal
down.Installthethreescrews(107),usinga
Torx(T20)screwdriveror7mm(9/32in.)socket
wrench.Tightenuntilthescrewsbottomouton
thehousing.
3.Installano-ring(108)oneachpilotpin(112).
Greasethepinsando-rings.Insertthepinsinto
thebearings,
narrow narrow
narrow
end󰘰rst.
4.Installu-cups(106)oneachactuatorpiston
(114),sothelipsofthepackingsfacethe narrow narrow
narrow
endofthepistons.
5.Lubricatetheu-cups(106)andactuatorpistons
(114).Inserttheactuatorpistonsinthebearings
(115), wide wide
wide
end󰘰rst.Leavethenarrowendof
thepistonsexposed.
6.Greasethelowerfaceofthepilotblock(116)and
installsoitstabssnapintothegroovesonthe
endsofthepilotpins(112).
7.Greasethelowerfaceofthevalvecarriage(105).
8.Installthevalvecarriage(105)soitstabsslipinto
thegroovesonthenarrowendoftheactuator
pistons(114).
103A6780E

Repair
9.Alignthevalvegasket(118)andcover(109)
withthesixholesinthecenterhousing(101).
Securewithsixscrews(107),usingaTorx(T20)
screwdriveror7mm(9/32in.)socketwrench.
Torqueto50-60in-lb(5.7-6.8N•m).
3A6780E11

Repair
Check Check
CheckValve Valve ValveRepair Repair Repair
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballsin
arangeofmaterials.Gasketkitsalsoareavailable.
Disassemble Disassemble
Disassemblethe the theCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Todrainthepump,partiallydisassemblethe󰘱uid
sectionasnotedbelow.
3.Removetheclamps(23)ontheoutletmanifold
(17)andremovethemanifold.
NOTE: NOTE:
NOTE:Usecarewhileremovingmanifoldsto
avoiddamagetocheckvalvecomponents.
4.Removeremainingclamps(23),manifolds(16),
gaskets(18),andcheckvalves(19,20).
5.Cleanandinspectgaskets(18),balls(19),ball
stops(20),andseatingsurfacesforanydamage
andreplaceasnecessary.
6.Tocontinuewithdiaphragmdisassembly,see
DisassembletheStandardDiaphragms,page13.
Reassemble Reassemble
Reassemblethe the theCheck Check CheckValves Valves Valves
NOTE: NOTE:
NOTE:Lubricateclampsandclampingsurfaceswith
waterproof,sanitarylubricant.
1.Reassembleballcheckassemblyinreverse
order.
2.Looselyattachthemanifoldstothe󰘱uidcovers.
Onceallcomponentsareproperlyaligned,
tightenclampshandtight.
123A6780E

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
NOTE: NOTE:
NOTE:Overmoldeddiaphragmsarecoveredin
OvermoldedDiaphragmRepair,page15.
Tools Tools
ToolsRequired Required Required
•Torquewrench
•5/8in.wrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
NOTE: NOTE:
NOTE:Centersectiongasketisdependenton
diaphragmmaterial.Ifchangingdiaphragmmaterial,
itmaybenecessarytoalsoreplacethecenter
sectionaircovergaskets.SeeDiaphragms,page23,
foraffectedaircovergaskets.
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Withboth󰘱uidcoversremoved,usingtwo5/8in.
wrenches,holdthewrench󰘱atsontheplates(Y)
ofeachdiaphragmassemblyandloosen.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.
5.Disassemblethefreediaphragmassembly.
6.Removeplate(12)withbolt(14)installed,
diaphragm(10),backer(11)ifpresent,andplate
(9).
7.Pulltheotherdiaphragmassemblyandthe
diaphragmshaft(24)outofthecenterhousing
(101).Holdtheshaft󰘱atswitha19mmopenend
wrench,andremovethediaphragmassembly
fromtheshaft.Disassembletheremaining
diaphragmassembly.
8.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
9.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(106),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
10.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
3A6780E13

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page18,
beforereplacingdiaphragms.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assemblediaphragm(10),backer(11)ifpresent,
andplate(9)ontoplate(12)withscrew(14).
Roundedsideofplate(9)shouldfacediaphragm.
MakesurethesidemarkedAIRSIDEfacesthe
centerhousing.
NOTE: NOTE:
NOTE:Threadlockermustbeappliedtoscrew
(14)asshownforalldiaphragmassemblies.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragmplate,
ifneeded.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew.
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Usinga5/8in.wrenchholdthewrench󰘱atsof
onediaphragmassemblyandtorquetheother
diaphragmto60-70ft-lb(81-94N•m).
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowfor󰘱uidcovermovementbeforesecuring
thecoversandclampsinplace.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidassembly.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
143A6780E

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•19mmopenendwrench
•O-ringpick
•Lithiumbasegrease
Disassemble Disassemble
Disassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page9.
2.Removethemanifoldsanddisassemble
thecheckvalvesasexplainedin
CheckValveRepair,page12.
3.Removetheclamps(21)fromthe󰘱uidcovers
(15),thenpullthe󰘱uidcoversoffofthepump.
4.Oncethe󰘱uidcoversareremoved,the
diaphragmonthesideofthepumpwhichwas
lastpressurizedwithairwillbeseparatedfrom
thecentersection/aircover.Thisallowsyouto
gripthediaphragms.
5.Toloosen,gripbothdiaphragmssecurelyaround
theouteredgeandrotatecounterclockwise.One
diaphragmassemblywillcomefreeandtheother
willremainattachedtotheshaft.Removethe
freeddiaphragm(10),screw(14)ifitremainsin
theshaft,andairsideplate(9).
6.Pulltheoppositediaphragmassemblyandshaft
(24)outofthecenterhousing(101).Holdthe
shaft󰘱atswitha19mmopenendwrenchand
removethediaphragmandairsideplatefrom
theshaft.
7.Inspectthediaphragmshaft(24)forwearor
scratches.Ifitisdamaged,inspectthebearings
(111)inplace.Ifthebearingsaredamaged,refer
toCenterSectionRepair,page18.
8.Reachintothecenterhousing(101)withan
o-ringpickandhooktheu-cups(110),thenpull
themoutofthehousing.Thiscanbedonewith
thebearings(111)inplace.
9.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
3A6780E15

Repair
Reassemble Reassemble
Reassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthecenter
section,followCenterSectionRepair,page18,
beforeyouputthediaphragmsbackon.
1.Lubricateandinstalltheshaftu-cups(106)so
thelipsface
out out
out
ofthehousing(101).
2.Assembleplate(9)ontodiaphragm(10)with
screw(14).Roundedsideofplate(9)should
facediaphragm.MakesurethesidemarkedAIR
SIDEfacesthecenterhousing.
1
Applyahigh-strengththreadlockerto
attachthescrewtothediaphragm.
2
Applyamedium-strengththreadlocker
totheshaftsideofthescrew(14).
3.Screwassembleddiaphragmassemblyintoshaft
(24)andhandtighten.
4.Greasethelengthofthediaphragmshaft(24),
andslideitthroughthehousing(101).
5.Assembletheotherdiaphragmassemblytothe
shaftasexplainedinstep2.
6.Gripbothdiaphragmssecurelyaroundtheouter
edgeandrotateclockwiseuntilbottomedonthe
shaft.
NOTE: NOTE:
NOTE:Applywaterproof,sanitarylubricanttothe
clamp(21)andclampingsurfaceofthecover(4,
15)toeaseassembly.
NOTE: NOTE:
NOTE:Toensureproperspacingandalignment
ofmanifolds,installclamps(21)looseenoughto
allowfor󰘱uidcovermovementbeforesecuring
thecoversandclampsinplace.
NOTE: NOTE:
NOTE:Useafoodgradeanti-seizelubricanton
theclampthreadstoaidinassembly.
7.Alignthe󰘱uidcovers(15)andthecenterhousing.
Securethecoverswiththeclamps(21)andhand
tighten.If,afterinstallingthe󰘰rst󰘱uidcover,the
opposingdiaphragmprotrudesawayfromthe
centerhousing,leavingagapbetweenthecenter
housingandthesecond󰘱uidcover,donottry
toforcethediaphragmintoposition.Instead,
completethefollowingproceduresinsteps7a–7i
toattachthesecond󰘱uidcover.
a.Removetheairvalvecover(B),thegasket
(C),andthepilotcup(D).Seetheimagein
stepi.
b.Withinthedrive,shiftthemainairvalve
carriage(E)awayfromtheinstalled󰘱uid
cover.Thiswillexposetheairpassagethat
feedstheassembledside.
c.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
d.Supplythepumpwith10–20psi(0.07–0.14
MPa,0.7–1.4bar)airpressure,justenough
tomovethediaphragm.Thediaphragm
willshiftsothesecond󰘱uidcoverwillseat
properly.Keeptheairpressureonwhileair
󰘱owsoutoftheexhaust.
NOTE: NOTE:
NOTE:Toomuchairpressuremaycausethe
diaphragmtodeformandseatincorrectly.
e.Installtheremaining󰘱uidcover.
f.Followthe
PressureReliefProcedure,page9.
Disconnecttheairsupplyfromthepump.
g.Removetheairvalvecover(B)andthe
gasket(C).
h.Lubricateandreinstallthepilotcup(D).
163A6780E

Repair
i.Reinstallthegasket(C)andtheairvalve
cover(B).Torqueallboltsaccordingto
instructionsinyourpumpmanual.
8.Reassembletheballcheckvalvesandmanifolds
asexplainedinCheckValveRepair,page12.
3A6780E17

Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Tools Tools
ToolsRequired: Required: Required:
•Torquewrench
•10mmsocketwrench
•9/16in.socketwrench
•Bearingpuller
•O-ringpick
•Press,orblockandmallet
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
NOTE: NOTE:
NOTE:Donotremoveundamagedbearings.
1.FollowthePressureReliefProcedure,page9.
Disconnectall󰘱uidandairlines.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheCheckValve,page12.
3.Removethe󰘱uidcoversanddiaphragms
asdirectedinDisassembletheStandard
Diaphragms,page13orDisassemblethe
OvermoldedDiaphragms,page15.
NOTE:Ifyouareremovingonlythediaphragm
shaftbearing(111),skipstep4.
4.Disassembletheairvalveasexplainedin
AirValveRepair,page9.
5.Usea10mmsocketwrenchtoremovethe
screws(104)holdingtheaircovers(103)tothe
centerhousing(101).
6.Removetheaircovergaskets(102).Always
replacethegasketswithnewones.Thegasket
partnumberdependsonthediaphragmmaterial
andwillaffectassemblyofmanifolds.Referto
thepartslisttoverifywhichgaskettouse.
NOTE: NOTE:
NOTE:Ifremovingthediaphragmshaftbearings
(111),useano-ringpicktoremovetheu-cups
(106)󰘰rst.
7.Useabearingpullertoremovethediaphragm
shaftbearings(111),airvalvebearings(115)
orpilotpinbearings(113).Donotremove
undamagedbearings.
8.Inspecttheu-cups.Replaceasneeded.
183A6780E

Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Installtheshaftu-cups(106)sothelipsface
out out
out
ofthehousing.
2.Insertnewbearings(111,113,and115)intothe
centerhousing(101),
tapered tapered
taperedend end end󰘰rst 󰘰rst 󰘰rst
.Using
apressorablockandrubbermallet,press-󰘰t
thebearingsoitis󰘱ushwiththesurfaceofthe
centerhousing.
3.Reassembletheairvalveasexplainedin
ReassembleAirValve,page10
4.Alignthenewaircovergasket(102)sothepilot
pin(112)protrudingfromthecenterhousing
(101)󰘰tsthroughtheproperholeinthegasket.
Thegasketpartnumberdependsonthe
diaphragmmaterialandwillaffectassemblyof
manifolds.Refertothepartslisttoverifywhich
gaskettouse.
5.Aligntheaircover(103)sothepilotpin(112)󰘰ts
inthemiddlehole(M)ofthethreesmallholes
nearthecenterofthecover.
6.Applyamedium-strengththreadlockertothe
threadsofthescrews(106).Installthescrews
(106),handtight.Usinga10mmsocketwrench,
torquethescrewsoppositelyandevenlyto
130-150in-lb(15-17N•m).Installthediaphragm
assembliesand󰘱uidcoversasexplainedin
Diaphragms,page23.
7.SeeReassembletheCheckValves,page12.
3A6780E19

Parts
Parts Parts
Parts
SP1B.xxxxmodelshown
203A6780E